JP3418333B2 - Base fabric for tufting - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a tufting base cloth for planting pile yarns which serve as a surface layer in tufting products such as carpets and artificial grass.

[0002]

2. Description of the Related Art Conventionally, tufting products have been constructed by laying pile yarns on a primary base cloth woven with uniaxially stretched polypropylene tape yarn, and then using polyvinyl chloride, ethylene-vinyl acetate copolymer or the like. A backing material manufactured by backing is often used.
This polypropylene tape yarn is usually heat-oriented and spun in the manufacturing process in order to impart high tenacity. However, since it is stretched, when it is woven and used as a base fabric, heat shrinkage easily occurs due to the heating of the backing process, the base fabric is wavy, and the needle penetration resistance during tufting is large and yarn breakage occurs. However, there are drawbacks such as the occurrence of such a phenomenon or a decrease in productivity, and the fact that the surface is smooth, resulting in poor adhesiveness with a backing material.

In order to improve the above-mentioned drawbacks, there has been an attempt to reduce the draw ratio to improve the heat shrinkability, but at a low draw ratio, the strength is lowered and the strength of the base cloth becomes insufficient. In addition, if the oiling process is performed to reduce the needle penetration resistance, the pile gripping force will decrease, and if the weaving density is increased to improve the pile gripping strength, the needle penetration resistance will increase. There were problems such as being lost.

[0004]

DISCLOSURE OF THE INVENTION The present invention provides a tufting product that is lightweight as a tufting product because it has a small penetration resistance of the needle to the base fabric in the tufting of pile yarns, a small heat shrinkage rate, and excellent adhesiveness with a backing material. The present invention provides a tufting base fabric that can obtain a pile yarn having a large gripping force.

[0005]

SUMMARY OF THE INVENTION The present invention provides a warp and / or
Alternatively, a crimped yarn made of a polyolefin tape yarn is used for a part or all of the weft yarn, which is a tufting base fabric.

The crimped yarn has a crimp ratio of 3 to 10
It is preferably 0%, and it is preferable that the polyolefin tape yarn is a split yarn that has been split.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION A tape yarn, which is a base of crimped yarn used in the present invention, is obtained by melt-extruding a polyolefin as a raw material with an extruder, forming a film by a T-die method or an inflation method, and slitting the film. It is formed by heat drawing and then heat treatment. The heat drawing is performed at a temperature not higher than the melting point of the raw material polyolefin and not lower than the softening point, and the draw ratio is preferably 3 to 15 times, more preferably 5 to 10 times. The fineness of the tape yarn is preferably 100 to 2000 denier (hereinafter abbreviated as d), and more preferably 300 to 1500 d, as the fibers constituting the base fabric.

In this tape yarn, it is more preferable to use a split yarn obtained by splitting a tape-like fiber as a fiber form. That is, by performing splitting and splitting, the penetration resistance of the needle is reduced and the adhesiveness with the backing material is improved. The method of forming the split yarn is, after forming the film in the same manner as the tape yarn, rotating the file, the needle, and the roll in which the blade is implanted at a high speed to damage or cut the film, and before or after the stretching. In the step of, it can be finely split and formed.

The above-mentioned polyolefin is preferably a highly crystalline polyolefin having a stretching effect and a high melting point, and specifically, polypropylene, propylene-ethylene copolymer, high density polyethylene, linear low density polyethylene, etc. Is mentioned. Of these, polypropylene is preferred, and among polypropylenes, highly crystalline polypropylene having an isotactic pentad fraction of 0.95 or more is more preferred. These polyolefins may be used alone or in combination of two or more.

In the present invention, the tape yarn is crimped and used as a crimped yarn for a part or all of the warp yarn and / or the weft yarn. The crimped yarn has a crimp ratio of 3 to
It is preferably 100%, more preferably 10 to 80%. If the crimping rate is less than 3%, it is difficult to achieve the object of the present application, and if the crimping rate exceeds 100%, the workability and the weaving efficiency are lowered and the cost is increased.

As a method for applying crimp to the tape yarn, there are a method of embossing through a heated gear, a method of applying false twist and heat setting, and a heating fluid using a heating fluid such as steam. The indentation method is preferable from the viewpoint of productivity.

In the heating fluid pushing method, the supplied tape yarn is fed to the heating fluid pushing nozzle through the feeding roll by the crimping process shown in FIG. 1, and the heating fluid pushing nozzle is a jet nozzle part. , A deposition section, and a cooling section. The tape yarn is supplied to the jet nozzle portion in a relaxed state and is sent to the deposition portion at a high speed by a high-pressure heating fluid having a propulsive force in the same direction as the traveling direction. In the deposition part, the fed tape yarn stalls rapidly, and due to the sudden slack due to this stall and the turbulent flow created by the high-pressure heating fluid, the crimping action such as sagging and entanglement occurs, and then the cooling part. The crimp is fixed to form a crimped yarn, and the yarn is wound on a take-up roll through a take-up roll. Air or steam is used as the high-pressure heating fluid used in this crimping process, and its temperature and pressure are not particularly limited, but the temperature is preferably 120 to 160 ° C., and the pressure is 1 to 8 kg. / Cm 2 is preferable.

The crimp ratio means the ratio of the difference between the supply speed and the take-up speed to the take-up speed in the above heating fluid indentation method, expressed as a percentage.

In the present invention, the above crimped yarn is woven using a part or all of the warp yarn and / or the weft yarn to form a base fabric. As a weaving method, a known loom such as a circular loom, a sulzer loom, a water jet loom, or an air jet loom can be used for weaving. As the weave structure, plain weave, twill weave,
Various shapes such as leno weave are applied. The implantation density is
Depending on the fineness and combination of threads used, it is usually 8 to 3
The range is 0 lines / inch.

In the above-mentioned base cloth, crimped yarns composed of tape yarns may be used for all of the warp and weft yarns of the base cloth, but the crimped yarns have a small heat shrinkage ratio and the gripping force of pile yarns. The crimped yarn has a large size, low needle penetration resistance, and excellent adhesiveness with the backing material, and has the strength, productivity, workability, and low cost of the non-crimped yarn. Is a part of the total warp and is preferably 30 to 70%, more preferably 40 to 60%. As a method of using the crimped yarn for a part of the total warp yarn, specifically, it may be used for a part of the warp yarn and a part of the weft yarn, but preferably a non-crimped yarn is used for the warp yarn, It is better to use crimped yarn for the.

After the conventionally used pile yarn made of nylon, polyester, polypropylene or the like is planted in the above-mentioned base cloth, backing processing is performed by a known method to obtain a tufting product. The backing layer is also mainly made of polyvinyl chloride, polyolefin resin, etc., which are the same as conventional ones.

The tufting product thus obtained has excellent adhesiveness with the backing material, so that the coating amount of the backing material can be reduced, and the product weight is reduced, which is lightweight and inexpensive. A tufting carpet is obtained.

The polyolefin used in the present invention includes
Other thermoplastic resins, or antioxidants, ultraviolet absorbers, light stabilizers, dispersants, lubricants, antistatic agents, pigments, inorganic fillers, cross-linking agents, without departing from the scope of the present invention,
You may mix | blend normally used additives, such as a foaming agent and a nucleating agent.

[0019]

EXAMPLES Example 1: Polypropylene (MFR = 1.2
g / 10 min., density = 0.90 g / cm3, Tm = 1
61 ° C), the film formed by the inflation method is slit into a width of 15 mm, and then the film is heat-stretched by a heat roll stretching method to about 6 times to form a tape shape, and then the blade-implanted roll is rotated at a high speed. A split yarn having a fineness of 1000 d was prepared by contacting with a machine and making a notch and then heat relaxation treatment. Further, the split yarn was heated to a temperature of 14
A split yarn crimped yarn was prepared by crimping using air at 0 ° C. and a pressure of 7.0 kg / cm 2. Of this split yarn, the non-crimped yarn is used as warp 22
18 threads per inch with crimped yarn as weft yarn
A plain cloth was formed by plain weaving at a striking density of books / inch.

Nylon pile yarn was planted on this base cloth by the tufting method. It was found that the needle penetration sound was low and the penetration resistance was low. Then, backing temperature 1 using ethylene-vinyl acetate resin on the back surface of this material.
Backing was performed at 30 ° C. to obtain a carpet. The backing material was applied at 550 g / m 2 and sufficient backing was possible. The pile gripping force of this carpet was 1.3 kg, and the gripping force was good.

Example 2 The same procedure as in Example 1 was repeated except that the crimped yarn and the non-crimped yarn of the split yarn used in Example 1 were alternately used as warp and weft yarns. The penetration resistance at the time of tufting to this base cloth was small, and the required coating amount of the backing material was 530 g / m 2. The pile gripping force of the carpet of Example 2 was 1.2 kg, and the gripping force was good.

Comparative Example 1: The same procedure as in Example 1 was carried out except that the non-crimped split yarn used in Example 1 was used as the warp and weft yarns. The penetration resistance of the needle during tufting to this base cloth was large, and the production rate was reduced by 5%. Further, the required coating amount of the backing material was 780 g / m 2, which was not preferable because the product weight increased.

Comparative Example 2: The same procedure as in Example 1 was carried out except that the uncrimped split yarn used in Example 1 was subjected to oiling treatment and used for the warp and weft. The needle penetration resistance during tufting to this base cloth was small, and the required backing material application amount was 650 g / m 2, which was relatively small, but the carpet pile yarn gripping force was insufficient at 0.7 kg. .

Comparative Example 3 The procedure of Example 1 was repeated, except that the non-crimped split yarn used in Example 1 was used as warp and weft to form a double woven base fabric. The penetration resistance of the needle during tufting to this base cloth was large, and the production rate was reduced by 10%. The gripping force of the pile yarn was improved to 1.5 kg, but the required coating amount of the backing material was 800 g / m 2, which was not preferable because the product weight increased.

[0025]

As described above, the tufting base fabric of the present invention is formed by using the crimped yarn made of the polyolefin tape yarn for a part or all of the warp and / or the weft, The needle penetration resistance during tufting is small and workability is excellent, and because the heat shrinkage rate is small, it is difficult for extra unevenness to occur on the base cloth or pile surface, and the adhesiveness with the backing material etc. in the backing process is good. A small amount of the backing material needs to be applied, and the resulting product such as a carpet has an excellent appearance, is lightweight, and has improved gripping force of the pile yarn.

[Brief description of drawings]

FIG. 1 is a flowchart of a heating fluid pushing crimping method which is an example of crimping.

[Explanation of symbols]

1 Heating fluid pushing nozzle 2 Jet nozzle 3 deposition areas 4 Cooling unit 5 supply rolls 6 Collection roll 7 entrance 8 suction port A supply tape yarn B crimped yarn

Claims (3)

(57) [Claims] 1. A tufting base fabric, characterized in that a crimped yarn made of a polyolefin tape yarn is used for a part or all of the warp and / or the weft. 2. The tufting base fabric according to claim 1, wherein the crimped yarn has a crimp ratio of 3 to 100%. 3. The tufting base fabric according to claim 1, wherein the polyolefin tape yarn is a split yarn subjected to split processing.